Process parameter optimization of laser additive manufactured AlCrFeNiTiVZr alloys using response surface technique

This study investigates the effect of laser power on the mechanical properties of equiatomic AlCrFeNiTiVZr high entropy alloy (HEA) fabricated using the Laser Additive Manufacturing (LAM) process. Laser powers of 300, 320, 340, 360, and 380 W were varied, while the scanning speed was held constant at 6.73 mm/s. The analyzed key performance indicators include microstructure, nanohardness, elastic modulus, and wear resistance. A combination of experimental evaluation and statistical modeling using design of experiments (DOE) and analysis of variance (ANOVA) was employed to identify optimal mechanical and tribological responses and to assess the relationships between laser parameters and alloy performance. The results indicate that higher laser power is crucial in achieving microstructural characteristics, which leads to a balance of hardness, strength properties and wear resistance. Predictions from the developed models suggest that the optimal power input should be within the range of 340–380 W. The validation process showed that the variation between what the models predicted and the actual experimental results is less than 0.05, confirming that the models are reliable for future predictions.